EOM-H800 6/02 REPLACES EOM-T8HP 3/01 - Pump
EOM-H800 6/02REPLACES EOM-T8HP 3/01
THE H800 HIGH PRESSURE PUMPA Powerful New Solution Wilden air-operated, double-diaphragm pumps have been thecost effective solution to problematic pumping applications forover 40 years. Inherent characteristics enable them to excel ina wide variety of applications where other pump types fail. Theintroduction of the H800 expands Wilden’s application range toinclude head pressures up to 250 psig. Wilden’s patentpending high pressure technology yields a 250 psig dischargepressure while maintaining many of the same standard Wildenpump features: Ease of operation Intrinsically safe Variable speed Ability to pass solids Variable pressure Ability to run dry Dead head capability No dynamic sealsThe Power Principle The H800 utilizes an integral power amplifier piston togetherwith two diaphragms to yield a pressure ratio of 3:1 (e.g. 80psig air inlet will develop pump discharge pressures up to 250psig). Air is simultaneously directed behind the amplifier pistonas well as one of the diaphragms via specialized air manifoldporting. The sum of these two surface areas is three timesgreater than the diaphragm surface area. Therefore, thesupplied air pressure is internally amplified which results in a3:1 pressure output ratio without sacrificing efficiencies.Air Powered Pump Two diaphragms (one located on each side of the pump) areconnected via shafts to the amplifier piston. As thecompressed air is routed to the backside of the power amplifierpiston, as well as one of the diaphragms, the diaphragmmoves outward and discharges the process fluid. At the sametime, the opposite diaphragm is pulled inward creating a pressure drop in the liquid chamber which allows fluid to enter thepump. As the amplifier piston and diaphragm complete theirstroke, the amplifier piston contacts a pressure relief valve.This pressure relief valve initiates air valve piston movementwhich re-directs the compressed air supply to the other side ofthe power amplifier piston and opposite diaphragm, therefore,reciprocating the pump.WILDEN PUMP DESIGNATION SYSTEMCAUTIONS! READ FIRSTTemperature Limitation:107 C (225 F) Operating Temperature107 C (225 F) Cleaning TemperatureCAUTION: Maximum temperature limits are based upon mechanical stress only. Certain chemicals will significantly reduce maximumsafe operating temperatures.SUGGESTED INSTALLATIONCAUTION: Verify that process fluid and cleaning chemicals arecompatible with all pump components. Consult Chemical Guide(RBG E-4) for chemical compatibility and temperature limitations.CAUTION: ALWAYS WEAR SAFETY GLASSES WHENPERFORMING INSPECTION, CLEANING, OR MAINTENANCE.READ ALL INSTRUCTIONS PRIOR TO INSTALLATION.CAUTION: Always drain and flush pump prior to performing maintenance.CAUTION: 85 psig maximum air inlet pressure. Do not exceed 250psig liquid discharge pressure.CAUTION: All piping, valves, gauges and other componentsinstalled on the liquid discharge must have a minimum pressurerating of 300 psig. TEFLON IS A REGISTERED TRADEMARK OF E.I. DUPONT CORP.
SECTION 1DIMENSIONAL DRAWINGWILDEN MODEL H800DIMENSIONS – H800ITEM METRIC 124.9TØ18.0STANDARD .5012.5012.8114.93.56ANSI300 # CLASS6.505Ø.75SECTION 2APUMP PERFORMANCE CURVEWILDEN MODEL H800Height .758.8 mm (297 8")Width .493.7 mm (197 16")Depth .539.7 mm (211 4")Weight . Stainless Steel 128.4 kg (283 lbs.)Air Inlet .1.27 mm (1 2")Inlet.5.08 mm (2")Outlet .5.08 mm (2")Suction Lift . 3.66 m Dry (12')9.14 m Wet (30')Displacement perStroke .1.67 l (0.44 gal.)Max. Flow Rate.359.6 l/m (95 gpm)Max. Size Solids.1.27 mm (1 2")Example: To pump 20 gpm against adischarge head of 125 psig requires 42psig and 38 scfm air consumption. (Seedot on chart.)1Displacement per stroke was calculated at 70psig air inlet pressure against a 75 psig headpressure.Flow rates indicated on chart were determined by actually pumping water incalibrated tanks.For optimum life and performance, pumps should be specified so that dailyoperation parameters will fall in the center of the pump performance curve.1
SECTION 2BSUCTION LIFT CURVE AND DATAMODEL H800Suction lift curves are calibrated forpumps operating at 305 m (1,000')above sea level. This chart is meant tobe a guide only. There are many variables which can affect your pump’soperating characteristics. The numberof intake and discharge elbows, viscosity of pumping fluid, elevation(atmospheric pressure) and pipe frictionloss all affect the amount of suction liftyour pump will attain.SECTION 3INSTALLATIONMODEL H800Months of careful planning, study, and selection efforts canresult in unsatisfactory pump performance if installation detailsare left to chance. Long term satisfaction can be assured ifreasonable care is exercised throughout the installationprocess.A muffler installed on the discharge port will reduce soundlevels below OSHA specifications. Sound levels will varydepending on air inlet and liquid discharge pressure; therefore,an aftermarket muffler may be needed to satisfy your ecosystem needs.Operator safety, liquid supply vessels, discharge sites, noiselevels, and other logistical factors usually dictate where thepump will be installed on the production floor. Within the framework of these and other existing conditions, every pump shouldbe located in such a way that four key factors are balancedagainst each other for maximum advantage.3. ELEVATION: The pump can be installed in such a way thatit has positive liquid inlet pressure or that a suction lift conditionexists. The maximum positive liquid inlet pressure is 10 psigwhen pump is in operation. Excessive positive liquid inlet pressure will reduce diaphragm life. The maximum suction lift islisted in Section 2 on page 1. To avoid loss of prime and erraticoperation in suction lift conditions, a foot valve can be installedat the end of the suction pipe.1. ACCESS: Pumps must be cleaned, inspected, and maintained on a regular basis in accordance with company orFederal protocol. To this end, the installation site should beeasily accessible allowing personnel room to carry out theirtasks. Ease of access will reduce downtime and maintenancecosts.2. AIR SUPPLY: Every pump location should have an air linelarge enough to supply the volume of air necessary to achievethe desired pumping rate. (Refer to the pump performancechart on page 1.) 3/4" air line is the minimum size required.Most applications require far less than the maximum air inletpressure of 85 psig. (Refer to pump performance chart.)For best results, the air supply should be free of pipe scaleand moisture. The use of an air filter installed just prior to thepump will eliminate the majority of any pipeline contaminates. Itis important that this filter does not restrict the air volume belowthe value required to achieve the desired pumping rate. Thefilter should be cleaned periodically to ensure its operationintegrity. The use of an oil with arctic characteristics (ISO 15-5wt) will reduce friction resulting in longer part life. An air regulator and needle valve installed on the air supply line enables theoperator to adjust pump speed and therefore, flow rate. Thepump’s supply air line should be connected to the top of themain air header so that water does not run down from the mainair header and into the pump. Excessive moisture can crystallize in the pump forming ice which blocks air ports causingreliability concerns.24. PIPING: Final determination of the pump site should not bemade until all piping concerns are addressed. The most advantageous pump site will involve the shortest and straightestsuction and discharge piping possible. Unnecessary elbows,bends, fittings, and components will increase head pressureand therefore decreasing efficiencies. Pipe sizes should beselected so as to keep friction losses to a minimum. All pipingshould be supported independently of the pump. Approximately18" of non-collapsible hose or expansion joints should beinstalled immediately prior to and after the pump to isolate itfrom the piping. This practice protects the pump and the pipefrom undue stress. Suction and discharge pipe size should beat least 2" diameter. If viscous product is being pumped, largerpipe size will reduce friction loss, lower air requirements and/orincrease flow rate. It is critical that all fittings and connectionsare airtight or a reduction in suction lift capability and/or flowrate will result. The pump system should be thoroughly flushedwith chemically compatible sanitizer prior to initiating line inproduction.NOTE: The air pressure regulator should be set so thatthe pressure does not exceed 80 psig. Pressure reliefvalve should be set at 260 psig so that pressure doesnot exceed safe operating pressures.
SECTION 4SUGGESTED OPERATIONMODEL H800Do not attempt to operate the pump until you have read theinstallation section (Section 3) of this manual. Verify that thepump is chemically compatible to the pumping fluid andassure that the discharge line is positioned in such a way thatthe pumped fluid will be contained. It is important that allpump hardware (nuts, bolts, etc.) be tightened.There are two ways of controlling flow rate which allow flexibility in design. 1) Adjusting the air inlet volume and/orpressure of the air supply line. As air volume is increased, thefaster the pump should reciprocate. As air pressure isincreased, the more head pressure the pump can overcome.2) Adjusting the discharge head with a valve. As pressureis increased, the flow rate should decrease.If the pump is to be installed as a batching or metering pump,the Wilden FCSI computerized batching computer can automatically operate the pump resulting in repeatable batchquantities.NOTE: The H800 has a minimum stroke rate of 2 strokes perminute. If fewer strokes per minute are required, consult thefactory.SECTION 5INSPECTION, CLEANING & MAINTENANCEINSPECTION: Periodic inspection reduces unscheduledpump downtime. Individuals responsible for inspecting andmaintaining lubrication levels for pumps should also check forany abnormal noise or leakage. Personnel familiar with thepumps’ construction and service should be informed of anyabnormalities that are detected.RECORDS: When service is required, a record should bemade of all necessary repairs and replacements. Over aperiod of time, such records can become a valuable tool forpredicting and preventing future maintenance problems andunscheduled downtime. In addition, accurate records make itpossible to identify pumps that are poorly suited to their applications.MAINTENANCE AND CLEANING: Read the entireEngineering, Operation and Maintenance Manual beforestarting any maintenance. To avoid serious injury or healthhazards, neutralize any chemicals present in the pump priorto maintenance. Before cleaning, check to make sure thatyour cleaning solution is chemically compatible with thepump’s elastomers and wetted parts. Some cleaning fluidscan cause severe damage to diaphragms, balls and seals.Ensure that cleaning fluid temperatures do not exceed therecommended limitations of elastomers and materials ofconstruction. When flushing the pump, disconnect the air linefrom the pump to avoid damaging diaphragms, pistons andshafts. Maximum inlet pressure for cleaning is 50 psig.SECTION 6TROUBLESHOOTINGPump will not run or runs slowly.1. Verify air pressure and volume required and availablebased on pump performance curve on page 1.2. Check air inlet screen and air filter for debris.3. Check for sticking air valve, remove and flush air valvewith cleaning fluid.4. Check for rotating piston in air valve. (Replace air valveend cap if needed.)5. Check for worn out air valve or pump amplifier pistonslipper seal. Replace if necessary.6. Check center block seals. If worn excessively, they willnot seal and air will simply flow through pump and out airexhaust. Use only Wilden seals as they are of specialconstruction.7. Check for sticking pressure relief valve. Clean or replaceassembly.2. Check for sticking ball checks. If material being pumpedis not compatible with pump elastomers, swelling may occur.Replace ball with the proper elastomers.3. Check to make sure all suction connections are air tight,especially hardware around intake balls.4. Verify pump is installed within its suction lift capability.Pump runs but little or no product flows.1. Check for pump cavitation; slow pump speed down toallow material to enter pumping chambers. Increase speedaccordingly.Product comes out air exhaust.1. Check for diaphragm rupture.2. Check tightness of hardware.3. Check for loose inner piston bolts.Pump air valve freezes.Check for excessive moisture in compressed air. Either installdryer or hot air generator for compressed air.Air bubbles in pump discharge.1. Check for ruptured diaphragm.2. Check tightness of hardware, especially at intake manifold.3. Check for loose inner piston bolts.3
SECTION 7ADIRECTIONS FORDISASSEMBLY / REASSEMBLYMODEL H800CAUTION: Before any maintenance or repair is attempted,the compressed air line to the pump should be disconnected and all air pressure allowed to bleed from pump.Disconnect all intake, discharge, and air lines. Drain thepump by turning it upside down and allow any fluid to flowinto a suitable container. Wetted flushing of parts may berequired prior to handling.The Wilden model H800 (Figure 1) is a high-pressure, air-oper-ated, double-diaphragm pump with all wetted parts of 316stainless steel. The center section consists of an aluminumpower amplifier cylinder, 316 S.S. air chambers, and a brassair valve. All O-rings and seals used in the pump are of specialmaterials and should only be replaced with factory-suppliedparts.To expedite parts ordering, please find an exploded view of theH800 at the back of this manual.DISASSEMBLYBefore actual disassembly is started, turn pump upside downand drain all liquid trapped in the pump into a suitablecontainer. Be sure to use proper caution if liquid is corrosive ortoxic. Read all instructions prior to disassembly.TOOLS REQUIRED 8" Open end wrench 8" Socket3 4" Socket and open end wrench1 2" Socket and open end wrench9 16" Open end wrench1" Socket5 16" Hex wrench1 4" Hex wrench5 64" Hex wrench5 32" Hex wrench50 ft. lbs. Torque wrench75Figure 14
SECTION 7BPRESSURE RELIEF VALVE DISASSEMBLYSTEP 1REMOVENUT/BOLTREMOVENUT/BOLTFigure 2Remove liquid chamber bolts/nuts adjacent to relief valves witha 3 4" socket and box end wrench. Loosen tubing nuts locatedby each pressure relief valve with a 9 16" wrench. (Figure 3.)Figure 3Figure 4Loosen pipe fitting and elbow with a 1 2" wrench so that reliefvalve can be removed. (Figure 4.)STEP 2Figure 5Remove each pressure relief valve with channel lock pliers. Ifpressure relief valve needs inspection, simply remove four flathead screws with a 5 64" hex wrench (Figure 6). Check forFigure 6Figure 7broken spring or damaged O-ring. Clean parts and reassemble. NOTE: Pressure relief valve is only sold as anassembly.5
SECTION 7CAIR VALVE DISASSEMBLYSTEP 1BLEEDER PORTSFigure 8Figure 9Figure 10Remove air valve and gasket by removing 4 hex bolts (1 4" hex wrench or socket).Remove snap ring which retains the airvalve end cap. (Figure 9.)Alternately pressurize top round (bleeder)holes with air gun until end cap pops offinto rag. (Caution: End cap may comeout with considerable force.)STEP 2LARGE AIR TUBESSMALL AIR TUBESFigure 11Figure 12Figure 13Check air valve, end cap O-ring, andguide pin for abrasion or chemical attack.Replace parts as needed.Remove air valve manifold by unloosening qty. 2 socket head cap screws with a5 16" hex wrench.Remove qty. 4 air tubes. (Note: 2 small, 2large.)6
SECTION 7DWETTED PARTS DISASSEMBLYSTEP 1Figure 14Figure 15Remove discharge manifold bolts with 2" wrench and socket.(Figure 14.) Remove discharge manifold and inspect ball cagearea for abrasion. (Figure 15.) Remove top valve balls andinspect for abrasion, chemical attack, or nicks. Replace as1Figure 16needed. Remove valve seat O-ring and valve seat (square sideup) and inspect for abrasion and chemical attack. Replace asneeded. (Figure 16.)STEP 2Figure 17Figure 18Figure 19Remove inlet manifold bolts with two 1 2"wrenches. (Figure 17.)Remove pump body from inlet manifoldwith the assistance of a crane or forkliftwith straps. (Note: the pump body isheavy.) Keeping the pump suspended,remove liquid chamber bolts located onfront side of pump with two 3 4" wrenches.Drain plugs are located on the bottom ofpower cylinder to drain liquid which mayhave entered the air chambers ifdiaphragm failed.Lower the pump body onto the air valvemounting base (flat side of power cylinder). Remove bolts on back side of unitand remove both liquid chambers.7
SECTION 7ECENTER SECTION DISASSEMBLYSTEP 1Figure 20Figure 21Rotate power cylinder so that front of power cylinder is accessible. Apply air pressure via air gun to air tube port and placesuitable object over relief valve port to create back-pressure.(Figure 20.) This operation will shift pump and invertdiaphragm for ease of disassembly. Place a 7 8" open endwrench on flats of shaft (other side of pump). Place a 1" socketon outer piston and remove diaphragm assembly by turningcounterclockwise. (Figure 21.) Shift assembly back over toother side by supplying air to opposite ports and then removethe opposite diaphragm assembly.STEP 2Figure 22Figure 23Remove inner piston by removing qty. 6 flat head screws with5 16" hex wrench. Replace diaphragm.Remove qty. 2 air chamber with gasket by removing qty. 6 flathead screws with a 5 16" hex wrench.8
STEP 3Figure 24Figure 25Remove power cylinder cover by removing qty. 12 hex headbolts with a 5 8" socket or wrench.Apply air pressure via air gun to relief valve port to pressurizepower cylinder and “pop-off” power cylinder cover and shaftbushing. Check seal integrity in shaft bushing and O-ring oncover.STEP 4GUIDE RINGSSLIPPER SEALFigure 26Figure 27Continue pushing power cylinder piston out by applying airpressure to pressure relief port.Pull out power cylinder piston with hand. Inspect and/orreplace power cylinder slipper seal and guide rings, which issold as an assembly. Clean center section and power pistonprior to reassembly.9
STEP 5Inspect shafts for wear. To replace, remove shafts from powerpiston. Place 7 8" open end wrenches on flats of shafts and turncounterclockwise. Pull shaft and bushing out.Figure 29Figure 30Figure 31Figure 32Figure 28SECTION 7FREASSEMBLYSTEP 1STEP 2STEP 3Assemble shafts to power piston (refer to Step 5above).Place power piston in vise with soft jaws (do notdamage or scratch piston) to insert new O-ring andslipper seal. TIP: Install slipper seal by using a stripof material (like an old O-ring) with back and forthmotions until slipper seal is situated over sealgroove. (Figure 29)Place power cylinder on blocks of wood (Figure 30).Insert new guide rings in outer grooves. Insert powerpiston into power cylinder. TIP: A conical (tapered)piece of cylindrical sheet metal (or other tool) willhelp hold the guide rings in place as they slide intothe power cylinder. (Figure 31)STEP 4STEP 5STEP 6STEP 7NOTE:SECTION 7GTap piston into cylinder with soft mallet. Verify thatslipper seal and guide rings are not damaged.(Figure 32)Check seal integrity in shaft bushing and O-ring oncover.Install cover as shown in Figure 33.Follow the reverse order of “disassembly instructions” starting with Section 7E, Step 3.Torque fasteners to specifications.TORQUESPECIFICATIONSCOMPONENTInner Piston Screws*Outer PistonAir Valve BoltsInlet/Discharge Manifold BoltsCenter Section Cover BoltsAir Chamber Screws*Liquid Chamber BoltsMAX. TORQUE54 m-N [40 ft. lbs.]114.75 m-N [85 ft. lbs.]9.45 m-N [7 ft. lbs.]16.2 m-N [12 ft. lbs.]54 m-N [40 ft. lbs.]54 m-N [40 ft. lbs.]54 m-N [40 ft. lbs.]Torque all hardware in an opposing torque sequence. LiquidChamber (LC) bolts may require periodic re-torquing. If LC preload torque values fall below 25 ft.-lbs. [34 m-N], re-torqueboth Liquid Chambers to 40 ft.-lbs [54 m-N]. LC torque loadingmust be even. If a bolt is tightened during an LC bolt checkprocedure, then all LC bolts must be tightened to ensure evendistribution.*Use #242 removable Loctite on fastener threads. (24 total.)10Figure 33
SECTION 8AEXPLODED VIEWH800AIR DISTRIBUTIONSYSTEM AND CENTERSECTION ASSEMBLY11
H800SECTION 8BEXPLODED VIEWWETTED PARTSASSEMBLYBAC12
SECTION 8CPARTS LISTING –WILDEN MODEL 505152DESCRIPTIONAir Valve Assembly 1End Cap w/Guide, NylonEnd Cap w/o Guide, NylonO-Ring, -220, BunaSnap Ring, S.S.Air Valve Screen, BronzeSHCS, 5 16"-18 x 21 4" S.S.Air Valve GasketSHCS, 3 8"-16 x 21 4"Nipple, NPT 1", GalvanizedElbow, 90 , 1" NPT, GalvanizedMufflerAir Valve Manifold, AluminumRelief Tube AssemblyPressure Relief Valve AssemblyRebuild Pressure Relief Seal Kit*Pipe, S.S.Pipe, S.S.O-Ring, -114, BunaPower Piston Seal Kit 2O-Ring, -379, BunaGuide Ring, Bronze-FilledSlipper Seal, PTFE-FilledO-Ring, -450, BunaPiston, Cylinder, AluminumBushing, Cylinder Piston, S.S.Shaft, S.S.Stud, Shaft, S.S.Cover, Center Section, AluminumGasket, Center Section, BunaHHCS, 7 16"-14 x 1", Grade 5Washer, 7 16", S.S.Plug, Pipe, 1 16"Bushing, Center Section 3Glyd RingO-Ring, -220, Buna (Item no. 4)Air Chamber, S.S.Center Section, AluminumWasher, 5 16", S.S.Hex Nut, 1 2"-13, S.S.HHCS, 1 2"-13 x 13 4, Grade 8Hex Nut, 5 16"-18, S.S.HHCS, 5 16"-18 x 1", S.S.Liquid Chamber, S.S.Outer Piston, S.S.Inner Piston, S.S.Inlet Manifold, S.S.Discharge Manifold, S.S.Diaphragm, Wil-Flex Ball, Valve, Wil-Flex O-Ring, Seat, Wil-Flex Valve Seat, S.S.Washer, 1 2", S.S.SFCHCS, 1 2"-13 x 1", 164282832322221124445624H800/SSAB/WF/WF/SWFANSI FLANGEDPART 840-03-6008-6220-03-60H800/SSAB/WF/WF/SWF/504DIN FLANGEDPART -6840-03-6008-6220-03-601Item #1, Air Valve Assembly, includes items #2, 3, 4, 5, 6.All boldface items are primary wear parts.Item #20, Power Piston Seal Kit, includes items #21, 22, 23, and 24*Also available with PTFE O-Rings & Balls 08-1200-55, 08-1080-553Item #34, Bushing, Center Section, includes qty. 1 of item #35 and #4.*Both sides of the pump must be rebuilt at the same time. One rebuild seal kit includes the parts to rebuild both sides.NOTE: Do not utilize the smaller O-ring for this pump model.213
increased, the more head pressure the pump can overcome. 2) Adjusting the discharge head with a valve. As pressure is increased, the flow rate should decrease. If the pump is to be installed as a batching or metering pump, the Wilden FCSI computerized batching computer can auto-matically operate the pump resulting in repeatable batch quantities.
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